Alignment of rotational shafts

ABSTRACT

For alignment of rotational shafts, two devices for attachment to circular faces of two shaft segments. Each of the two devices has a laser photoelectric device for ascertaining a dimension of displacement of the two shafts from a desired axis of rotation relative to each other. Each of the two devices having a base surface with two linear contact edges designed to engage with a circumferential surface of a shaft and to ensure alignment between the device and an axis of rotation of the shaft to within a tolerance compatible with alignment tolerances of the shaft. Each of the two linear contact edges includes at least two terminal end regions and a center region together defining a line contact at linear intersection of two surfaces meeting at a non-zero angle linear contact edges designed to affix and release from the shaft surface, and to ensure parallel alignment between the device and an axis of rotation of the shaft to a precision allowing measurements to within tolerances required by machinery driven by the shaft. The base surface of at least one of the devices has been modified from its commercially-delivered condition to provide raised rails designed to improve tactile feedback of to a user of the alignment between the base and an axis of rotation of the shaft, and has affixed thereto two rails designed to improve tactile feedback of to a user of the alignment between the base and an axis of rotation of the shaft. Each base has a magnet and a switch to vary magnetic flux for affixation and release from the shaft surface. Each device has brackets designed to securely and reproducibly position laser photoelectric devices relative to the base and axis of rotation of the shaft. The attaching includes a human placing at least one of the devices slightly askew relative to the axis of rotation of the shaft, and the human gently twisting the device to allow the liner contact edges to seat on the circumferential surface of the shaft, to provide tactile feedback to the human to confirm parallel alignment between the at least one device&#39;s laser photoelectronic device and the axis of rotation of the shaft.

This application is a continuation of U.S. application Ser. No.16/658,072, filed Oct. 19, 2019, Alignment of Rotational Shafts, nowissued as U.S. Pat. No. 11,300,404; which is a non-provisional of U.S.Provisional App. Ser. No. 62/748,464, filed Oct. 21, 2018. The '072 and'464 applications are incorporated by reference.

BACKGROUND

This application relates to measurement and testing of alignment orangles of rotational axes of rotational shafts using photoelectricdetection means.

When machinery with machine shafts is disassembled for maintenance,during reassembly, various shaft sections must be realigned to highprecision.

The traditional method of measuring shaft alignment is to glue a dialindicator or one or more photodetectors onto a shaft coupling face oronto a fixed location on the circumference of the shaft. Variousmeasurements are taken of the two shaft segments with respect to eachother. The dial indicator is used to measure the radial distance betweenthe couplings. Then gauge blocks are used to measure the gap at 0°, 90°,180°, and 270°. Then oil lift pumps are turned on to allow the shaft tobe rotated by 90°. Then the lift oil pumps are shut off to allow theshaft segments to settle into their journal bearings. Then, the dialindicator and four gauge block measurements are repeated at 90°. Thedial indicator measurement is used as a control to account for change inthe gauge block measurements between rotational locations. Then theshafts are rotated twice more, to 180° and 270°, and the measurementsrepeated. Thus, sixteen gauge block measurements are taken, four dialindicator measurements are taken, and the lift oil pumps are used fourtimes. A fifth rotation is required to get to a full 360° rotation, toverify the measurement against the original dial indicator measurementat 0°.

From those measurements, linear displacements and angular offsets arecomputed, then position and/or angle of one or both of the shaftsections are adjusted, and the measurements are repeated until the shaftsegments are aligned to within the necessary tolerance.

SUMMARY

In general, in a first aspect, the invention features an apparatus formeasuring alignment of two shafts. Two magnetic bases each have twolinear contact edges designed to engage with a circumferential surfaceof a shaft at least 10 inches in diameter and to ensure alignmentbetween the base and an axis of rotation of the shaft to within atolerance compatible with alignment tolerances of the shaft. Each basehas a switch to vary magnetic flux for affixation and release from theshaft surface. Brackets attached to the bases are designed to attachlaser photoelectric devices, the photoelectric devices designed tomeasure shaft misalignment.

In general, in a second aspect, the invention features a method. Tocircular faces of two shaft segments each at least 10 inches indiameter, two devices are attached. Each device has a base surfacedesigned to engage with a circumferential surface of a shaft at least 10inches in diameter, and each base surface having features designed toaffix and release from the shaft surface, and to align with therotational axis of the shaft to a precision allowing measurements towithin tolerances required by machinery driven by the shaft. Each of thetwo devices has laser photoelectric devices for ascertaining a dimensionof displacement of the two shafts from a desired axis of rotationrelative to each other. The attaching including moving the devices toallow the linear contact edges to bite the circumferential surfaces ofthe shaft segments to assure parallel mounting. The bases and bracketsare used to take multiple measurements by the laser photoelectricdevices, rather than by rotation of the shaft. (Rotation of the shaftsis not altogether precluded; rather, the base and photoelectric devicesreduce the need for rotations between measurements, perhaps to zero.)

Embodiments of the invention may include one or more of the following.The laser photoelectric devices may be a one-laser system or a two-lasersystem. The brackets may be adaptable to allow the measurements to betaken through bolt holes of shaft couplings. The brackets may bedesigned to allow the laser photoelectric devices to face each other.The bases may be magnetic, with on/off switches to apply or withdrawmagnetic flux for affixation or release of the base from the shaft. Abottom surface of at least one of the two bases may be modified from itscommercially-delivered condition to provide raised rails designed toimprove tactile feedback of to a user of the alignment between the baseand an axis of rotation of the shaft. At least one of the two bases mayhave affixed thereto two rails designed to improve tactile feedback ofto a user of the alignment between the base and an axis of rotation ofthe shaft.

The above advantages and features are of representative embodimentsonly, and are presented only to assist in understanding the invention.It should be understood that they are not to be considered limitationson the invention as defined by the claims. Additional features andadvantages of embodiments of the invention will become apparent in thefollowing description, from the drawings, and from the claims.

DESCRIPTION OF THE DRAWINGS

FIGS. 1(a) to 1(c) are photographs showing a time sequence of use of adevice to measure shaft alignment.

FIGS. 2(a) to 2(d) are photographs of a device to measure shaftalignment, and component parts of the device.

FIGS. 3(a) to 3(m) are photographs of a device to measure shaftalignment, and component parts of the device.

FIGS. 4(a) to 4(i) are photographs showing a time sequence of use of adevice to measure shaft alignment.

DESCRIPTION

The Description is organized as follows.

-   I. Overview-   II. Alternative configuration-   III. Components-   IV. An operational use case    I. Overview

Referring to FIGS. 1A to 1C, laser alignment system 100 may bepositioned on two segments 110 of a rotating shaft to measure alignmentof the rotational centerlines 112 of the two shaft segments. Alignmentmay have four parameters: linear offset or displacement (horizontal andvertical), and angular parallelism in two dimensions. Once alignment ismeasured, the shafts may be adjusted to ensure that the two rotationalcenterlines 112 are aligned to within desired tolerances. Laseralignment system 100 may have a laser unit 102 and sensor unit 104, ormay be a two laser/sensor system. A device of bases 210 andphotodetectors may be configured to reproducibly position laser unit 102and sensor unit 104 relative to each other on the two shafts 110, sothat sufficient measurements may be taken to align the two segments ofthe shaft. For example, in power plants where the turbine rotors orshafts are very large and/or hard to rotate, the device may allowobtaining reproducible, accurate, and precise measurements by moving thelaser and sensor from place to place, reducing need to rotate the shaftsfor measurement.

In FIG. 1B, on the right shaft coupling, zero degrees is marked at thepoint where a bar is glued to hold a dial indicator 118. The bar anddial indicator 118 are used in the traditional testing method, to ensurethat use of the laser device 100, 102, 104 gives readings consistentwith the traditional measurement technique.

In the example of FIGS. 1A to 1C, the coupling for two segments 110 of apower plant steam turbine shaft may be 50 inches (127 cm) or more indiameter. The turbine manufacturer's specifications may require that thetwo segments be aligned to some tolerance, typically forhorizontal/vertical linear alignment, 0.002″ to 0.004″ (50 to 100 μm),and for angular alignment, to within 0.002″ to 0.004″ in difference ingap across the diameter of the coupling (that is, an angle that iswithin arc sin(0.004/50) of perfectly parallel, that is, about 0.0045°or about 16 arcseconds.

Referring to FIGS. 1A and 1B, brackets 200 may be designed to positionlaser unit 102 and sensor unit 104 on the outer circumference of twoshafts or coupling segments. Brackets 200 may be designed so that laserunit 102 and sensor unit 104, or a two laser/sensor system, may bereliably aligned parallel with the axis 112 of the shaft.

In some cases, measuring optical photoelectronic devices such those fromPrüftechnik of Germany, including Prüftechnik's Rotalign Touch system orRotalign Ultra system may be used (the two web pageshttps://www.pruftechnik.com/us/products/alignment-systems-for-rotating-machinery/shaft-alignment-systems/rotalign-touch.htmlandhttps://www.pruftechnik.com/us/products/alignment-systems-for-rotating-machinery/shaft-alignment-systems/rotalign-ultra-is.htmlas of the filing date, and ROTALIGN touch brochure, ROTALIGN touchWhitepaper, and ROTALIGN Ultra iS brochure are incorporated byreference). Among other alternatives are laser shaft alignment systemsmade by FixturLaser of Sweden, or Easy-Laser of Sweden, both of whichare two-laser systems, or the Stealth Series from Hamar Geolasers ofDanbury, Conn.

In the single-laser system shown in FIGS. 1A and 1B, laser unit 104 ison the right. Sensor unit 104 that receives the laser beam from laserunit 102 is on the left. Laser unit 102 allows the laser beam to beadjusted for up/down and left/right aim. Sensor unit 104 detects the x ylocation and angle of incidence of the incoming laser beam, so long asthe laser beam enters within a 2° tolerance window (1° in each directionoff center). Optics internal to sensor unit 104 create a first detectorplane near the front surface of sensor unit 104, and a second virtualdetector plane behind the first detector plane by about 12 inches, sothe combination of x y readings from the two image planes allows precisemeasurement of the angle of incidence. In addition, laser unit 102 andsensor unit 104 have inclinometers so each can detect its own rotationalangular orientation. Other systems such as a 2 laser/sensor systemcomprise of two laser/sensor combination units used in a similarfashion.

Referring to FIG. 1C, to calculate misalignment, multiple measurementstaken by laser unit 102 and sensor unit 104 may be taken and combined toascertain linear and angular alignment. To take these measurements,sensor unit 104 and laser unit are moved from position to positionaround the circumference of two corresponding smooth circular surfaces110 of the two shafts, to collect multiple measurements for thecalculation. At each position, the base 210 provides sufficientprecision in the coupling of the device to the shaft or coupling so thatmeasurements can be taken that are meaningful with respect to thetolerances. For example, if the shafts must be aligned to within 16arcseconds, the base-to-shaft alignment precision should be reproducibleto within 4 arcseconds, 2 arcseconds, or 1 arcsecond depending onacceptable tolerances. In other applications, shaft alignment precisionto within 8 arcseconds, 12 arcseconds, 16 arcseconds, 20 arcseconds, 30arcseconds, or other measurements may be acceptable.

Measurement at three positions may be mathematically sufficient tomeasure alignment, if the apparatus is known to be perfect. Taking moremeasurement points may improve accuracy, provide redundancy fordetection and correction of methodological error or misalignment withinthe apparatus, and reduce the number of trial-and-error alignmentadjustments. Eight to fourteen measurement points may be desirable.

In FIG. 1C, laser unit 102 and sensor unit 104 are still on the topcenter of the couplings 110 for the two shaft sections, as they were inFIGS. 1A and 1B. A handheld computer 122 receives data from laser unit102 and sensor unit 104 to, first, to confirm that the laser beam ishitting the sensor's detectors within the front window and within the2°-wide angle permissible incidence. Once the laser and detector arelined up, then, second, a finger press of a “capture measurement point”button on the computer screen causes computer 122 to capture thefollowing measurements:

-   -   The x and y linear position at which the laser beam hits each        detector plane of sensor unit 104    -   The angle at which the laser beam hits the detector, based on        differences between the forward and back image planes of the        detector    -   The angular orientations of laser unit 102 and of sensor unit        104. Because they will be progressed around the circumference of        the circular shaft or coupling, the angular orientation of laser        unit 102 and of sensor unit 104 translate into angular location        on that circumference.

After each measurement is taken, laser unit 102 and sensor unit 104 aremoved around the circumference of the shaft, and the process isrepeated: laser unit 102 and sensor unit 104 are lined up, and thenanother finger press captures the next measurement point. Computer 122may display the total number of measurement points taken, and the anglesubtended by the measurements.

II. Alternative Configuration

FIGS. 2A, 2B, 2C, and 2D show a second configuration of brackets 200. Insome cases, the outer circumference of the shaft coupling may have gearteeth or some other non-smooth or non-circular surface, which may limitability to affix a measurement device. In those cases, laser unit 102and sensor unit 104 may be mounted on the shaft, and the laser beam shotthrough the bolt holes of the two coupling (visible in FIGS. 4B and 4F).

In such cases, rods and blocks 200 may be arranged to hold laser unit102 and sensor unit 104 in front of mounting base 210, down close to theshaft surface. Brackets 200 may provide a rigid and reproducibleaffixation of the laser and sensor unit 104 as low as touching thesurface of the shaft. Magnetic base 210 shown (shown in grey in FIGS. 2Aand 2B) is 55 mm in height, so it can be seen that the apertures oflaser unit 102 and sensor unit 104 may be placed within 2 inches of theshaft surface.

The brackets may be designed to provide a range of heights so as to holdlaser unit 102 and sensor unit 104 several inches above the surface towhich base 210 is attached, to allow the laser and sensor to “see over”an obstruction.

III. Components

FIGS. 3A to 3I show the components of brackets 200, from the bottom up.

Referring to FIG. 3A, for attaching and detaching laser unit 102 andsensor unit 104, it may be desirable to use a base 210 of the type usedwith dial indicators. For example, the Noga On/Off Magnet base 210,model DG0039, is available from Noga Engineering & Technology of Israel,http://www.noga.com/Products/base/Bases/DG0039/On%7Cfs%7COff_magnet_-_DG0039This model has a base 50 mm (2 inches) wide, and 120 mm (4.8 inches)long, with a V groove 220 in the bottom.

V-groove 220 provides two linear contacts against a curved machinesurface. In other configurations, the bottom surface of base 210 mayhave two rails 242. As will be shown in FIGS. 4B, 4C, 4F, and 4G, thetwo linear contacts allow a person to feel the base “bite” as it seatswith high precision to the curved surface of a large-diameter shaft.This provides reproducible seating parallel to the shaft axis 112.

Other similar bases 210 are available from Noga and other manufacturers.The appropriate base 210 for use with a given shaft may be chosen basedon the configuration of the shaft. Generally, longer is better, toimprove precision of alignment for parallelism, up to the width ofwhatever face the base 210 is to be attached to, and subject to ahuman's ability to manage the weight and length of the device. Forlarger-diameter shafts, bases 210 of wider width may be preferred. Forsmaller diameter shafts, bases 210 with narrower widths may bepreferred. For non-ferrous shafts/couplings or large diameters, a widerV-block may be used, or magnetic base 210 may be replaced with a chainor strap fastener.

Magnetic base 210 has a magnet that can be switched on and off. The onposition is labeled with a “+,” and the off position is labeled with a“−,” which can be seen in FIGS. 3A and 3H. When the magnet is turnedoff, the position of the bracket may be adjusted to high precision. Thenwhen the magnet is turned on, the magnet holds the bracket securely withminimum risk of positional perturbation.

Referring to FIGS. 3B to 3 (g), various components (blocks 232 and rods234) may be configured to hold the Prüftechnik laser unit 102 and sensorunit 104, or other two-laser system, in a consistent orientationrelative to magnetic base 210. In FIGS. 3B and 3C, a mounting block ofaluminum is machined to be flat, and to provide several sets of mountingholes for rods. Any surface coating, etc. may be removed to ensure thatthe mounting block screws to magnetic base 210 with essentially norocking or play (little enough to not erode the necessary tolerances).Holes may be drilled and tapped in base 210 and mounting block forfixing screws.

FIG. 3C shows components laid out for assembly. Magnetic base 210 is atthe lower right. Mounting block 232 may be screwed to magnetic base 210to affix the two together. Then comes a smaller rod holder block 232that can be combined with the holes in the mounting block to hold two ofthe rods 234 and clamp them. This rod holder block 232 has screws toaffix the rod holder block to the mounting block in any one of severaldifferent positions. Then come two rods 234 to be inserted through therod holder block into one of the sets of holes in the mounting block.Two screws in the rod holder block may allow the rod holder block to beclamped down to hold the rods tight.

In some uses, the Prüftechnik laser unit and sensor unit 104 may bemounted on these two rods 234.

In other cases, where it is desired to hold laser unit 102 and sensorunit 104 closer to the surface of the shaft (like FIGS. 1B, 1C, and 1D)to shoot through bolt holes, a medium size block 232 mounts on the tworods, and in turn holds two more rods 234 that extend back down, wherethese two further rods may hold laser unit 102 or sensor unit 104. Themedium block has screws that allow it to clamp the four rods it affixes.

The multiple sets of holes 236 in the mounting block 232 allows formounting laser unit 102 and sensor unit 104 in different places relativeto magnetic base 210. Using the center set of holes (as in FIGS. 3D, 3E,3F, 3G, and 3I) tends to give a steadier, more reproducible mounting,because (as discussed above in connection with FIGS. 4C, 4F, and 4G),adjustment of laser unit 102 and sensor unit 104 to face each othertends to be a bit easier. Using a forward set of holes (as in FIGS. 2Athrough 2D allows the device to be configured for the bolt holeconfigurations.

FIGS. 3D and 3E show the first mounting block 232 screwed onto magneticbase 210 and then the rod holder block in the center position of themounting block.

FIG. 3F shows two rods mounted into the rod holder block. The rods areheld tight by clamping down on screws in the side of the rod holderblock.

Referring to FIGS. 3G, 3H, and 3I, laser unit 102 and sensor may now bemounted onto these rods. After tightening all clamps to ensure rigid andstable mounting, the device is now ready to take readings.

Magnetic base 210 with linear or rail contact, as shown in FIGS. 3A and3B, provides tactile feedback to a human who is to position the devicesinto measuring position. Other configurations may provide contact pointswith appropriate geometry—reasonably long in the dimension parallel tothe shaft, up to the length of a smooth section of the shaft coupling,and at a width appropriate to the diameter of the shaft or coupling.Other mounting base devices, and configurations for contact points, maywork as well. Especially with larger shaft diameters, in the range of 50inches and more, long-contact solid parallel rails, or a V-groove 220,may give better tactile feedback.

Referring to FIGS. 3J and 3K, a bottom surface of magnetic base 210 mayhave a pair of parallel grooves 240 milled in, leaving outer edge rails242 in higher relief (compare the milled surface of FIGS. 3J and 3K withthe “factory” condition of the bottom surface shown in FIG. 3A). Thehigher-relief rails 242 may provide greater “bite” into the shaftsurface than the factory configuration of the base. Greater “bite” mayin turn provide greater tactile feedback to the user when rails 242 anddevice become aligned parallel to axis of rotation 112.

Referring to FIGS. 3L and 3M, external rails 242 may be affixed ontomagnetic base 210. Externally-affixed rails 242 will somewhat increasethe width between the bite rails, which tends to reduce alignment error.In some cases, external rails 242 could be longer than magnetic base210, which again may reduce angular error. External rails 242 may beespecially helpful in allowing a user feel the base “bite” as it comesinto alignment with large diameter couplings (greater than 50 inches),and may also work well on smaller diameters. The wider design may alsobe helpful when an external surface of the shaft is rough, as there isless surface contact and the user can find areas of the coupling wherethere are smooth contact points. External rails 242 may preferably bemade of a ferromagnetic metal (like iron or low-alloy steel) so thatwhen magnetic base 210 is turned on, rails 242 become magnetic (as ifthey “conduct” magnetism) and become magnetically attractive to thesurface of the shaft.

A rail spacing of about 50 mm (2 inches) or a little more, and length ofabout 120 mm (4.8 inches) seems to be a “sweet spot.” At thosedimensions, the length is long enough that the linear errors inaffixation of base 210 to shaft 110 translate into sufficiently smallangular errors. As dimensions get larger, mass and resilience of thedevice tend to damp the tactile feel as the magnet “bites” the surfaceof the shaft.

Alternative configurations for the contact points may be curved,semicircular, or rollers, to provide touches at tangent points betweenthe shaft surface and the base contacts. These may be more applicablefor smaller-diameter shafts. For shafts below 10 inches in diameter,point contacts may be adequate. As shaft diameters increase above 10inches, to 15, 20, 25, 30, 35, 40, 45, and 50 inches, the advantage oflinear contact increases.

Fixed linear contacts may provide friction with the shaft surface thatimproves stability of the mounting. Rollers and smaller-contract roundedcontacts may lack this frictional contact to prevent the smallperturbations or gravitational sag that would disturb readings.

Magnetic affixation may be desirable, because magnets have a continuouscharacter. A tension mechanism that may be tightened with a threadedtension nut may also be desirable. In contrast, mechanical connectionsbased on chains and gears have a character that varies over the lengthof each chain link or gear tooth. In an application where high precisionis essential, it may be preferred to avoid such variability.

The components of base 210 and brackets 200 may be designed to reduceinternal resilience and play, to provide rigidity and consistentorientation of laser unit 102 and sensor unit 104 as they are moved fromposition to position along the circumference of the shaft or coupling.The rods and rod holders should be stiff enough that the weight of laserunit 102 and sensor unit 104 introduce no measurable “sag” as the deviceis rotated. If laser unit 102 and/or sensor unit 104 is slightlynon-parallel or non-perpendicular relative to its base, the user canidentify bad points using software in computer 122 to subtract it out,so long as the error is stable and consistent. While high precision ofangle and dimension may be desirable, they are less crucial thanrigidity and consistency.

IV. An Operational Use Case

FIGS. 4A to 4I show an operational use case.

Referring to FIG. 4A, before measurements begin, various measurementsare taken, and entered into computer 122. These measurements may beprecise to ordinary measuring-tape precision, for example, to thenearest ⅛ inch (3 mm). For use cases using the Prüftechnik laser system,the following measurements may be taken and entered into computer 122:

-   -   coupling diameter    -   the axial distance from the coupling center to the sensor    -   the axial distance from the coupling to the front foot of the        bearing, motor, etc. (the front point at which shims would be        inserted to change the alignment of the shaft)    -   the axial distance foot-to-foot of the bearing, motor, etc. (the        distance between the front shim point and rear shim point)        For other laser devices with fewer capabilities for        self-calibration, other dimensions may be measured and entered:    -   the diameter of the coupling (or whatever surface laser unit 102        and sensor unit 104 will be placed on), about 34 inches in the        example of FIGS. 4B to 4I.    -   the height of the laser beam and sensor unit 104 receptor        aperture above the coupling, about two inches in the        configuration of FIGS. 2C and 2D, or about seven inches in the        example of FIGS. 4B to 4I.    -   in an alternative, the two preceding measurements may be        combined an entered into computer 122 as the distance from the        shaft center to the laser beam and shutter aperture, about 32        inches in the example of FIGS. 4B to 4I.    -   the gap between the coupling, about 1 inch in the example of        FIGS. 4B to 4I.

Referring to FIG. 4B, a measurement begins by placing sensor unit 104 onits coupling hub 110. Magnetic base 210 is placed slightly skewed orcrooked, with the magnet turned off. When the magnet is turned on, thehuman can feel it pull, and can twist base 210 until the V-groove 220 orrails 242 on the base “bites” or “clicks” to the surface of the shaft orcoupling when it becomes perfectly parallel to the shaft rotationalcenter.

Because of this askew-and-adjust placement, it may be desirable toposition the mounting rods to hold the emission lens of laser unit 102and aperture lens of sensor unit 104 over the center of magnetic base210. If the lenses are centered (or, as a proxy, if the entire laserunit 102 and sensor unit 104 are centered) over their respectivemounting bases, then as each base is twisted and adjusted to “bite” andalign with the shaft surface, then the relevant components only changeangle, not location. This eases the tasks of trial-and-error alignment.

Referring to FIG. 4C, next, laser unit 102 is positioned on the oppositecoupling. First, the laser beam dot is positioned to just miss thecenter of the shutter on sensor unit 104. On the shutter there is asmall circle in raised plastic and that is the center of x and ydetectors of sensor unit 104. While maintaining the laser beam on theshutter center, the human lines up laser unit 102 and turns on themagnet and twists it to “bite” the surface of the shaft to lock thelaser beam into place on the sensor aperture. If positional guesses wereaccurate, then the twisting of laser unit 102 puts the laser beam spotexactly in the center of the shutter, over the sensor aperture lens. Theuser may also set the laser side first, then adjust the sensor second toline them up. This method may be preferred when measuring throughbolt-holes of the couplings.

Referring to FIG. 4D, once both units 102, 104 are locked into place bytheir respective magnetic bases 210, the human slides back the shutteron sensor unit 104.

Referring to FIG. 4E, computer screen 122 shows that the laser beam ishitting the sensor unit's detector on center. On the right side of thescreen, several angles are shown, reflecting readings of theinclinometers internal to laser unit 102 and sensor unit 104. In thelower center of the screen of FIG. 4E, a red semicircle with a bluecenter wedge shows the angle of incidence of the laser beam, and theblue wedge represents the 2° range of permissible incidence angles. Ifthe white needle falls within the blue wedge, this indicates that thelaser beam is sufficiently aligned to allow a measurement reading. Ifall the alignments are within the measurement range of the device toallow a meaningful reading, then computer 122 displays a circle-M in thecenter of the screen to indicate that the sensor's detector can see thelaser beam, and that the laser beam and sensor detector are aligned totake a measurement point. The human provides a finger touch, andcomputer 122 captures the measurement point. Other alignment systems mayhave a different method of collecting data points.

Referring to FIG. 4F, with the first measurement point completed, thehuman unlocks sensor unit 104 by turning the magnet off, and thenphysically moves laser unit 102 and sensor unit 104 to new positions onthe shaft or coupling circumference. There is no requirement for anyexact distance, because the inclinometers interior to the laser unit 102and sensor unit 104 will detect the new angle and compensate. Thedistance should be enough so to cover the total circumference by asufficient number of measurement points. Again, three may bemathematically sufficient, if the devices are known to be perfect. Moremeasurement points may provide additional precision, redundancy tocompensate for measurement errors, and reduce the number of adjustmentsrequired.

The process repeats: first, sensor unit 104 is moved, and placed againstthe shaft circumference slightly askew, then the base's locking magnetis turned on, then sensor unit 104 is turned until the human feels thelinear contacts bite. Then, the human unlocks the laser unit's magnet,moves laser unit 102 into position (FIG. 4G) so that laser unit 102 ispositioned slightly askew and the laser beam hits sensor unit 104slightly off the center circle of the sensor's shutter, then the humanturns on the laser unit base's magnet. Then the human twists base 210for laser unit 102 until it bites, and hopefully the laser beam hits thecenter circle of the sensor unit's shutter (FIG. 4H). Position andorientation of laser unit 102 may be readjusted until the position andangle all line up with the laser beam on the center of the circle on thesensor's shutter.

Once everything is lined up, then (FIG. 4I) the human slides back theshutter on sensor unit 104, and the circle-M on computer screen 122indicates that the laser beam, image detector in sensor unit 104, andcomputer 122 are ready for a next measurement point.

Computer 122 will tell when each reading has been recorded, and how manydegrees of arc of the shaft are covered by the measurements. The wholeprocess is repeated over the whole exposed rim of the coupling, untilfurther measurements are blocked by the turbine casing or the full 360°is covered.

Referring again to FIG. 4E, when a sufficient number of measurementshave been taken over a sufficient extent of the shaft circumference,computer screen 122 will show a blue checkmark at the lower right of thescreen. The human may then touch that blue check mark to tell computer122 that measurements are complete.

The human may take a second set or several sets of measurements as arepeatability check to make sure the measurements are consistent.

When computer 122 and human are satisfied, then computer 122 may displaya result screen to allow the human to review a computed misalignmentresult. Computer 122 may display a vertical offset, a horizontal offset,and horizontal and vertical angularity or gaps/diameter.

For the convenience of the reader, the above description has focused ona representative sample of all possible embodiments, a sample thatteaches the principles of the invention and conveys the best modecontemplated for carrying it out. Throughout this application and itsassociated file history, when the term “invention” is used, it refers tothe entire collection of ideas and principles described; in contrast,the formal definition of the exclusive protected property right is setforth in the claims, which exclusively control. The description has notattempted to exhaustively enumerate all possible variations. Otherundescribed variations or modifications may be possible. Where multiplealternative embodiments are described, in many cases it will be possibleto combine elements of different embodiments, or to combine elements ofthe embodiments described here with other modifications or variationsthat are not expressly described. A list of items does not imply thatany or all of the items are mutually exclusive, nor that any or all ofthe items are comprehensive of any category, unless expressly specifiedotherwise. In many cases, one feature or group of features may be usedseparately from the entire apparatus or methods described. Many of thoseundescribed variations, modifications and variations are within theliteral scope of the following claims, and others are equivalent.

The invention claimed is:
 1. An apparatus, comprising: two bases, eachhaving two linear contact edges designed to engage with acircumferential surface of a shaft and to ensure alignment between thebase and an axis of rotation of the shaft to within a tolerancecompatible with alignment tolerances of the shaft, each of the twolinear contact edges including at least two terminal end regions and acenter region together defining a line contact at linear intersection oftwo surfaces meeting at a non-zero angle; and brackets attached to thebases designed to securely and reproducibly position laser photoelectricdevices relative to the axis of rotation of the shaft, the photoelectricdevices designed to measure shaft misalignment.
 2. The apparatus ofclaim 1, wherein: a bottom surface of at least one of the two baseshaving been modified from its commercially-delivered condition toprovide raised rails with the line contact.
 3. The apparatus of claim 1,wherein: the laser photoelectric devices include a laser unit and sensorunit of a single laser system.
 4. The apparatus of claim 1, wherein: thelaser photoelectric devices include a laser units of a dual lasersystem.
 5. The apparatus of claim 1, wherein: the brackets beingdesigned to allow affixation of the respective laser photoelectricdevice at a range of heights, the low end of the range having therespective laser electronic device with its bottom surface touching ornearly touching the surface of the shaft, the upper end of the rangeholding the respective laser electronic devices with its bottom surfaceat three inches above the surface of the shaft.
 6. The apparatus ofclaim 1, wherein: the bases being magnetic, with on/off switches toapply or withdraw magnetic flux for affixation or release of the basefrom the shaft.
 7. The apparatus of claim 1, wherein: the bases havingmechanical elements designed to successively affix and release the baseto and from the shaft.
 8. A method, comprising the steps of: attachingto circular faces of two shaft segments, two devices: each of the twodevices having an engagement surface designed to engage with acircumferential surface of a shaft, each having two linear contact edgesdesigned to engage with a circumferential surface of a shaft and toensure alignment between the device and an axis of rotation of the shaftto within a tolerance compatible with alignment tolerances of the shaft,each of the two linear contact edges including at least two terminal endregions and a center region together defining a line contact at linearintersection of two surfaces meeting at a non-zero angle; and each ofthe two devices having a laser photoelectric device for ascertaining adimension of displacement of the two shafts from a desired axis ofrotation relative to each other the attaching including attaching thedevices at several points on the circular faces on the shaft with norotation of the shaft between attachments, each attachment using tactilefeedback as the linear contact edges of the engagement surfaces bite thecircumferential surfaces of the shaft segments, to assure parallelmounting.
 9. The method of claim 8, further comprising: a base unit, thebase providing at least one of the engagement surfaces and a bracketdesigned to mount and hold the laser photoelectric device in alignmentrelative to the line contact.
 10. The method of claim 9, wherein: abottom surface of at least one of the two bases having been modifiedfrom its commercially-delivered condition to provide raised railsdesigned to improve tactile feedback of to a user of the alignmentbetween the base and an axis of rotation of the shaft.
 11. The method ofclaim 9, wherein: the base has affixed thereto two rails designed toimprove tactile feedback of to a user of the alignment between the baseand an axis of rotation of the shaft.
 12. The method of claim 8,wherein: the laser photoelectric devices include a laser unit and sensorunit of a single laser system.
 13. The method of claim 8, wherein: thelaser photoelectric devices include a laser units of a dual lasersystem.
 14. The method of claim 8, wherein: the brackets are designed toallow affixation of the respective laser photoelectric device at a rangeof heights, the low end of the range having the respective laserelectronic device with its bottom surface touching or nearly touchingthe surface of the shaft, the upper end of the range holding therespective laser electronic devices with its bottom surface at threeinches above the surface of the shaft.
 15. The method of claim 8,wherein: the bases are magnetic, with on/off switches to apply orwithdraw magnetic flux for affixation or release of the base from theshaft.
 16. The method of claim 8, wherein: the bases have mechanicalelements designed to successively affix and release the base to and fromthe shaft.